MXPA02006911A

MXPA02006911A - Lancing as a position locator in an electrical outlet box.

Info

Publication number: MXPA02006911A
Application number: MXPA02006911A
Authority: MX
Inventors: Brian Macdonald
Original assignee: Thomas & Betts Int
Priority date: 2001-07-31
Filing date: 2002-07-12
Publication date: 2003-02-12
Also published as: US20030024927A1; US6715625B2; CA2392836A1; CA2392836C

Abstract

An electrical receptacle has at least one side wall defining a receptacle interior, wherein the side wall includes an edge defining a receptacle opening and further includes at least one raised protrusion formed thereon and an aperture formed therein as a result of forming the protrusion. The protrusion has a banking surface substantially parallel with the opening edge for positioning the receptacle and the protrusion substantially occludes access to the receptacle interior through the aperture of the side wall.

Description

I LAUNCH AS A POSITION LOCATOR IN AN OUTPUT ELECTRICAL BOX CROSS REFERENCE WITH RELATED REQUESTS This application claims the benefit of United States Provisional Application No. 60 / 309,021 filed on July 31, 2001.

FIELD OF THE INVENTION The present invention relates generally to an electrical receptacle and more particularly to an electrical receptacle having projections formed thereon as position locators.

BACKGROUND OF THE INVENTION The means for placing an output electrical box with respect to a structural member to which it is mounted are well known in the art. For example, United States Patent No. 4,842,165 to Nattell discloses an electrical outlet box having positioning elements similar to those shown in Figure 1. Referring to Figure 1, the electrical outlet box 10 includes fingers of 12 formed on the side walls 14 of the box. The positioning fingers 12 are bent transversely from the side wall 14 around fold lines extending parallel to the front of the box 10. The positioning fingers 12 are stagnant against a structural element, such as a cross member of a cross member. wall 16, to place the electrical box at a predetermined distance in front of the structural element. Typically, the distance between the front of the electrical box 10 and the stagnation surface of the fingers 12 is equal to the thickness of a subsequently installed wall so that the front of the box 10 will be leveled against the finished wall. A disadvantage of the placement finger arrangement shown in Figure 1 is that these fingers can only be formed at the ends of a side wall. Therefore, its use is limited. Another disadvantage is that these outward projecting fingers typically include pointed edges making the handling of the electrical box difficult and inconvenient to install. Another example of an electrical outlet box having positioning means is described in U.S. Patent No. 5,579,939 to Bourassa and shown in Figure. Here, the outlet electrical box 20 includes appendages or tabs 22 projecting outward from a side wall 24 of the box. Again, the tongues or appendages 22 are spaced an equal distance from the edge of the front opening of the box and are installed back to a side of an adjacent support structure 26 to position the box 20 at a predetermined distance in front of the structure. The tongues 22 are formed by cutting small portions of the side wall 24 and bending the cut portions perpendicularly, leaving openings or holes 27 in the side wall. Although here the tabs 22 can be placed on either side of the side wall, these typically still include sharp edges that make the handling of the box difficult. Another disadvantage of the configuration shown in Figure 2 relates to the resulting holes or openings 27 formed in the side wall of the box as a result of the cutting process. North American electrical standards require that an electrical outlet box be manufactured in a manner that does not allow a rod with a diameter of 0.1 18 inches to pass simultaneously through both walls lateral Therefore, an electrical outlet box formed with the tabs 22, according to Figure 2, can have the tabs only in one of the side walls in order to meet the standards. If the tabs 22 were formed in both side walls, a rod with a diameter of 0.1 18 inches would be able to pass through the holes 27 formed in the two side walls. Said box would not be in compliance with the electrical standards of North America. Another positioning element found in the two electrical boxes of Figures 1 and 2 is an arrangement of raised convex projections or protuberances 28 formed in one or both side walls of the box. Nevertheless, these protuberances or gibs 28 only assist in laterally separating the electrical box at a distance away from the support structure and do not provide the rearward alignment of the electrical box to the rear. Accordingly, it would be desirable to provide an outlet electrical box that has a positioner to assist in the back-to-back alignment of the box that meets North American electrical standards and is easier to handle when installed.

BRIEF DESCRIPTION OF THE INVENTION The present invention is an electrical receptacle having at least one side wall defining an interior of the receptacle. The side wall includes a border defining an opening of the receptacle and further includes at least one raised projection formed thereon. The projection has a sealing surface substantially parallel to the opening edge and the projection substantially obstructs access to the interior of the receptacle through an opening formed as a result of forming the projection on the side wall. ...-.- a - * -.- ^.! l ffl l iHigÜÉri The salient can be of any form. For example, the projection may be arcuate or beak shaped and may be completely integral with the side wall. In a preferred embodiment, the sealing surface of the projection is also substantially perpendicular to the side wall and is spaced a predetermined distance from the opening edge of the receptacle. The projection is a substantially integral outwardly bent portion of the side wall, whereby a 0.1-inch diameter rod can not be inserted through the opening below the projection. The side wall preferably includes two raised projections, which have coplanar sealing surfaces that are substantially parallel with the opening edge. The side wall further preferably includes at least one convex rim formed thereon. The convex rim has a predetermined height to separate the side wall at a predetermined distance away from the structural mounting element. Preferably, the receptacle includes an upper wall, a bottom wall, a rear wall and two side walls forming an open rectangular box.

The first side wall includes a first raised projection formed thereon and a second side wall includes a second raised projection formed thereon. The first and second projections each have a sealing surface substantially parallel to the opening edge, and the projections close the access to the interior of the interior of the receptacle through the first and second side walls.

In a preferred embodiment, the sealing surface of the first projection is spaced at a predetermined distance from the opening edge and the sealing surface of the second projection is separated at a second predetermined distance from the opening edge. The present invention also involves a method for forming a positioning projection for an electrical receptacle. The method includes the steps of cutting . . -a-tf ,, -.- ^^ - two grooves or grooves substantially parallel to a side wall of an electrical receptacle and bending a portion of the side wall between the grooves outward to form the positioning projection. The slits are cut substantially parallel with the opening edge of the receptacle so that the positioning projection will be formed having a sealing surface substantially parallel with the opening edge. By forming the projection in this manner, the positioning projection will substantially close the access to the interior of the receptacle through the side wall. A preferred form of the electrical receptacle having projections as a positioner as well as other embodiments, features and advantages of this invention will be apparent from the following detailed description, which will be read in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 illustrates a prior art electrical outlet box having positioning fingers. Figure 2 illustrates a prior art electrical outlet box having locating tabs projecting outwardly. Figure 3 a perspective view of the electrical box formed in accordance with the present invention. Figure 4 is a side view of a lancer taken along line 4-4 of Figure 3. Figure 5 is a perspective view of an alternative embodiment of a protrusion formed in accordance with the present invention. ._ - _____ J ___ J ____ ------ _-- *., .., ^ ____ áa ___. J .. ^^., ^ - _ ^ _- J______.

Figure 6 is a perspective view of another alternative embodiment of a projection. Figure 7 is a perspective view of yet another alternative embodiment of a projection.

DETAILED DESCRIPTION OF THE PREFERRED MODALITIES Referring now to Figure 3, there is shown an electrical receptacle 30 formed in accordance with the present invention. The electrical receptacle 30 shown in Figure 3 includes upper and lower walls 32 and a rear wall 34 and side walls 36a and 36b forming an open rectangular box having an interior 37. However, the receptacle 30 can have any shape. At least, and preferably both, side walls 36a and 36b are formed with at least one projection, called a lance, 38a and 38b projecting outward from the side wall. Preferably, each side wall 36a and 36b include two projections or lances 38a and 38b positioned at a predetermined distance from the front edge of aperture 42 of the case 30. The projections 38a on a side wall 36a can be placed at a first predetermined distance 40 on the edge 42 and the projections 38b on the other side wall 36b can be placed at a second predetermined distance 41 from the edge. For example, the standard sizes of the wall boards are 1/2 inch and 3/8 inch. Accordingly, a series of projections 38a may be spaced half a inch from the edge 42 and the projections 38b on the opposite side wall may be spaced 3/8 inch from the edge. This provides the receptacle 30 with the alternate front-to-back placement depending on which side wall 36a or 36b is mounted to the support structure 46.

The projections 38a and 38b are preferably formed using known lancera formation techniques. In particular, the projections 38a and 38b are formed in the same side walls 36a and 36b by a die cutting parallel grooves 43 in the side walls. The slots 43 are formed parallel to the opening edge 42 of the side wall 36a and 36b. The die further bends the part of the side wall between the slits outward to form the projection 38a and 38b. Thus, in the preferred embodiment, the projection 38a and 38b are not completely cut from the side wall 36a and 36b, thus not leaving sharp edges. Additionally, the projections 38a and 38b substantially close or block the resulting opening 39 in the side wall 36 so that a rod with a diameter of 0.118 inches will not be able to fit into the interior 37 of the electrical box 30. As a result, the projections 38a and 38b may be provided on both side walls 36a and 36b and the box 30 still meet the electrical standards of North America. As also shown in Figure 4, the projections 38 formed in this manner include a sealing surface 44 which is parallel to the opening edge 42 of the receptacle and preferably perpendicular to the side wall 36. The sealing surface 44 of the projection 38 is used to position the electrical box 30 at a predetermined distance in front of a support structure 46. If the two projections 38 are formed in the side wall 36, the sealing surfaces 44 of each projection must be coplanar and be aligned parallel with each other. the front edge 42 of the electrical box 30 to ensure the level alignment of the box. The projections 38 can have many shapes as long as the projections include a sealing surface parallel with the front opening of the receptacle and while the projection substantially closes the access to the interior of the receptacle through the side wall. The projections 38a and 38b shown in Figures 3 and 4 are arcuate in shape and are formed by cutting parallel grooves 43 in the side wall 36a and 36b. From this way, the side wall 36a and 36b has an opening 39 and the projection 38a and 38b is integral with the side wall at its longitudinal ends. Figure 5 shows a projection that is completely integral with the side wall 36, whereby the opening in the side wall is not formed. Figure 6 shows a protrusion 52 that is triangular or peaked and Figure 7 shows a protrusion 54 that is similar to the protrusion 38 shown in Figures 3 and 4, but is integral with the sidewall 36 only at one end . In each of the embodiments shown in Figures 5 to 7, the projection 50 as 52 and 54 includes a sealing surface 44 parallel to and spaced from the open edge 42 of the receptacle. Additionally, each of the projections 50, 52 and 54 closes or blocks access to the interior of the receptacle through the side wall 36. The protrusions discussed in this manner thus far are all formed from a portion of the side wall. of the receptacle box. However, it is conceivable that a projection having a sealing surface can be formed separately from the receptacle and fixed to the receptacle to cover an opening formed in the side wall of the receptacle. In such a case, the sealing surface is positioned over the opening of the side wall to close or block access to the interior of the receptacle through the opening of the side wall. The sealing surface can then be fixed to the side wall by known fastening techniques, for example by welding or riveting. Returning to Figure 3, the side walls 36a and 36b preferably further include one or more convex ridges or protrusions 48 formed therein. The flanges 48 are formed having a height 49 selected to provide a pre-determined spacing between the support structure 46 and the receptacle 30 at the time of installation. To install the receptacle 30, the sealing surfaces 44 of the projections 38 are staggered up against the front face of the support structure 46 and the convex ridges 48 are supported against the side wall. _-_.-__, ___ L_t_ ^. J AM _-_ .., - ~ .t ~ __ * Í ___ ¿_ * ... ^ .-. - _ .. _ ^ __ ^ _ ___-__- »-. > of the support structure. The receptacle 30 can then be secured to the support structure in a known manner, for example, by screws or nails. Therefore, the electrical receptacle 30 formed in accordance with the present invention provides a positive afterthical positioning with respect to a support structure. Additionally, the projections of the present invention can be formed on the two side walls. If the separation of the projections with respect to the front edge of the receptacle is the same in both side walls, the proper orientation of the receptacle during installation is less critical. If the separation is different, the installer can orient the receptacle to select the desired placement, depending on the thickness of the chosen finished wall. Because the openings formed in the side walls during the lancera formation process are closed, a rod will not be able to pass through the two side walls of the box and, therefore, the North American electrical standards are met. . Generally, the lanceras are of flat or smooth shape not leaving sharp edges. Therefore, the box is easier to handle during installation. Although illustrative embodiments of the present invention have been described herein with reference to the accompanying drawings, it should be understood that the invention is not limited to those precise embodiments and that various other changes can be made here by a person skilled in the art. technique without departing from the scope or spirit of the invention.

Claims

CLAIMS 1. An electrical receptacle comprising at least one side wall defining a receptacle interior, the side wall including a edge defining a receptacle opening and said side wall further including at least one raised projection formed thereon and an aperture formed therein. inside as a result of forming said projection, the projection having a sealing surface substantially parallel with the opening edge, and wherein the projection substantially closes the access into the receptacle through the opening of the side wall. A receptacle according to claim 1, comprising an upper wall, a lower wall, a rear wall and two side walls forming an open rectangular box. A receptacle according to claim 1, wherein the sealing surface of the projection is substantially perpendicular with respect to at least one side wall. A receptacle according to claim 1, wherein the sealing surface of the projection is spaced a predetermined distance from the opening edge. A receptacle according to claim 1, wherein the projection is a substantially integral outwardly bent portion of the side wall. A receptacle according to claim 1, wherein the projection substantially closes the opening whereby a rod with a diameter of 0.118 inches can not be inserted through the opening. 7. A receptacle according to claim 1, wherein the The side wall includes two raised projections, each projection having a watertight surface substantially parallel with the opening edge. A receptacle according to claim 7, wherein the sealing surfaces of the two raised projections are coplanar. A receptacle according to claim 1, comprising first and second opposite side walls defining an interior of the receptacle, each of the side walls including a edge defining an opening of the receptacle and said first side wall further including a first raised projection formed thereon and the second side wall further including a second raised projection formed thereon, each of the first and second projections having a sealing surface substantially parallel with the opening edge, and wherein the first and second projections second substantially close the access to the interior of the receptacle through the first and second side walls. A receptacle according to claim 9, wherein the first side wall further includes a first opening formed as a result of forming the first projection and the second side wall further includes a second opening formed as a result of forming the second projection , wherein the first and second projections substantially close respectively the access to the interior of the receptacle through the first and second openings of the first and second side walls. 1. A receptacle according to claim 10, wherein the first and second projections respectively close substantially the first and second openings so that a rod with a diameter of 0.1 18 inches can not be inserted through the two. first and second side walls through the first and second openings. 12. A receptacle according to claim 9, wherein the sealing surface of the first projection is separated at a first predetermined distance from the opening edge and the sealing surface of the second projection is separated at a second predetermined distance from the edge of opening. A receptacle according to claim 9, wherein the sealing surface of the first projection is substantially perpendicular to the first side wall and the sealing surface of the second projection is substantially perpendicular to the second side wall. 14. A receptacle according to claim 1, wherein the side wall further includes at least one convex rim formed thereon, the ridge having a predetermined height for separating the side wall at a predetermined distance away from the structural mounting element. 15. A receptacle according to claim 1, wherein the projection is arcuate in shape. 16. A receptacle according to claim 1, in the projection is peak-shaped. 17. A receptacle according to claim 1, in the projection is partially integral with the side wall. An electrical receptacle comprising at least one side wall defining an interior of the receptacle, a side wall including a edge defining an opening of the receptacle and said side wall further including at least one opening formed therein and a surface of sealing arranged on the opening, said sealing surface being substantially parallel with the opening edge, wherein the sealing surface substantially closes the access to the interior of the receptacle through the opening of the side wall. í __________ fi _ ^ _____ i ______ * ___ ái_í 19. A receptacle according to claim 18, wherein the sealing surface is formed from a part of the side wall. A method for forming a positioning projection for an electrical receptacle comprising the steps of: cutting two substantially parallel grooves in a side wall of the electrical receptacle, the grooves being substantially parallel with the opening edge of the receptacle; and folding a part of the side wall between the slots outward to form the positioning projection, whereby the positioning projection has a sealing surface substantially parallel with the opening edge, and wherein the positioning projection substantially closes the opening. access to the interior of the receptacle through the side wall. * - * ^